FUEL TANK REPLACEMENT 1991 CLIPPER 1.8

Hi all
I'm replacing the petrol tank and filler neck after lots of trouble with rust particles in fuel lines.  I'd be grateful for some advice on a couple of points:-
1. The manual says remove the rear section of the exhaust - is this the short section including the back box? or does a longer section (which I would call the middle section) also need to be removed? It seems to me that removing only the back box section wouldn't give enough clearance to drop the tank.
2. The manual also says that the back axle does not need to be detached, but just lowered a bit to allow the tank to come out. Any advice about how low it needs to go and whether or not the brake pipes could be left in place (the flexible pipes would not allow for very much lowering, I think)?
3. Anything else need to come off?
I am working with the car on stands. so I don't have very much room underneath.
Grateful for any advice.
cheers
den
 

1. Soak the axle mounting bolts after brushing the rust off of them in a penetrant ie: PB_Blaster for a few days, spraying them about 4 times a day.
2. Do NOT USE A BREAKER BAR AND SOCKET TO REMOVE THEM or you will torque shear the studs off.
3. Use a Pneumatic or Electric Impact wrench.

Jack the Car and support it on the Pinch Welds infront of the Tires and Jack it as high as you can get it.  Chock the front wheels (tyres).

Take car when lowering the axle about the 5 inches or you will break the rear hoses that connect to the rear hard brake lines, you might want to replace them as they are easier to get to with the axle down prior to going back.  

These are about all I can think of.  beside Good Luck.

I did mine about a month ago it's easy enough to do just a pain to wiggle it out , and it's about 20 times harder to go back in - it can be done on your own but best to do it with two of you.

The higher you can jack it up the better!

Take the opportunity to get waxoil on everything while it's out.

I didn't take the exhaust off, but if I had of it would of made it MUCH easier

Get plenty of fuel line to change them + the breathers at the same time - might as well while you have it out

I didn't take axle off, I managed to drop it quite low - I have just enough play in the brake lines.

I used 4 axel stands and 2 jack's (3 actually at one point!) but you could do it with 2 and a single jack, having the extra ones just help support and hold things as you drop and remove bits and I put it back in on my own so it helped me hold it in place while I did the bolts etc.

Many thanks for the pics - very useful!
Did you just undo the shocks bottom bolts?
Also did you detach the flexible brake hoses between the hard brake lines, because you seem to have been able to lower the axle quite a bit more than 5-6 inches?
Much appreciated!!
Den

Hey

yep, i removed the bottom shock bolts.

i did not remove or undo any of the brakes - my hoses had enough play / length to drop it that far although i am not sure if its the same on all models.